EP1994978A1 - Verfahren zur Herstellung von Methylmethacrylat durch Veresterung während der Oxidation - Google Patents

Verfahren zur Herstellung von Methylmethacrylat durch Veresterung während der Oxidation Download PDF

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Publication number
EP1994978A1
EP1994978A1 EP07010480A EP07010480A EP1994978A1 EP 1994978 A1 EP1994978 A1 EP 1994978A1 EP 07010480 A EP07010480 A EP 07010480A EP 07010480 A EP07010480 A EP 07010480A EP 1994978 A1 EP1994978 A1 EP 1994978A1
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EP
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Prior art keywords
oxidation
methacrylic acid
methyl methacrylate
methacrylate
process according
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EP07010480A
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English (en)
French (fr)
Inventor
Torsten Balduf
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Roehm GmbH Darmstadt
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Evonik Roehm GmbH
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Application filed by Evonik Roehm GmbH filed Critical Evonik Roehm GmbH
Priority to EP07010480A priority Critical patent/EP1994978A1/de
Priority to CN201510090209.6A priority patent/CN104761447A/zh
Priority to CNA2007101290656A priority patent/CN101311159A/zh
Priority to JP2010509756A priority patent/JP5511655B2/ja
Priority to KR1020097024424A priority patent/KR101517633B1/ko
Priority to PCT/EP2008/052225 priority patent/WO2008145417A1/en
Priority to US12/598,438 priority patent/US8829235B2/en
Priority to TW097118761A priority patent/TWI455921B/zh
Publication of EP1994978A1 publication Critical patent/EP1994978A1/de
Withdrawn legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C67/00—Preparation of carboxylic acid esters
    • C07C67/03—Preparation of carboxylic acid esters by reacting an ester group with a hydroxy group
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C57/00—Unsaturated compounds having carboxyl groups bound to acyclic carbon atoms
    • C07C57/02—Unsaturated compounds having carboxyl groups bound to acyclic carbon atoms with only carbon-to-carbon double bonds as unsaturation
    • C07C57/03—Monocarboxylic acids
    • C07C57/04—Acrylic acid; Methacrylic acid
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C51/00—Preparation of carboxylic acids or their salts, halides or anhydrides
    • C07C51/16—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation
    • C07C51/21—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen
    • C07C51/25—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen of unsaturated compounds containing no six-membered aromatic ring
    • C07C51/252—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen of unsaturated compounds containing no six-membered aromatic ring of propene, butenes, acrolein or methacrolein
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J8/00—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
    • B01J8/02—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds
    • B01J8/04—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with stationary particles, e.g. in fixed beds the fluid passing successively through two or more beds
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C51/00—Preparation of carboxylic acids or their salts, halides or anhydrides
    • C07C51/16—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation
    • C07C51/21—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen
    • C07C51/23—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen of oxygen-containing groups to carboxyl groups
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C67/00—Preparation of carboxylic acid esters
    • C07C67/08—Preparation of carboxylic acid esters by reacting carboxylic acids or symmetrical anhydrides with the hydroxy or O-metal group of organic compounds
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C67/00—Preparation of carboxylic acid esters
    • C07C67/39—Preparation of carboxylic acid esters by oxidation of groups which are precursors for the acid moiety of the ester
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C69/00—Esters of carboxylic acids; Esters of carbonic or haloformic acids
    • C07C69/52—Esters of acyclic unsaturated carboxylic acids having the esterified carboxyl group bound to an acyclic carbon atom
    • C07C69/533—Monocarboxylic acid esters having only one carbon-to-carbon double bond
    • C07C69/54—Acrylic acid esters; Methacrylic acid esters
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/04—Acids; Metal salts or ammonium salts thereof
    • C08F220/06—Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/10—Esters
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/10—Esters
    • C08F220/12—Esters of monohydric alcohols or phenols
    • C08F220/14—Methyl esters, e.g. methyl (meth)acrylate
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/10—Esters
    • C08F220/12—Esters of monohydric alcohols or phenols
    • C08F220/16—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms
    • C08F220/18—Esters of monohydric alcohols or phenols of phenols or of alcohols containing two or more carbon atoms with acrylic or methacrylic acids
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/582—Recycling of unreacted starting or intermediate materials

Definitions

  • the invention relates in general to a process for production of methacrylic acid, to a process for production of methyl methacrylate, to an apparatus for production of methacrylic acid, to an apparatus for production of methyl methacrylate, to a process carried out in the apparatus, to methacrylic acid obtainable by the process, to methyl methacrylate obtainable by the process, to methacrylate esters, to a process for preparation of a polymer comprising at least one methacrylic acid, methyl methacrylate or methacrylate ester monomer unit, to a polymer comprising at least one methacrylic acid, methyl methacrylate and/or methacrylate ester monomer unit, to a process for preparation of a composition comprising at least one of methacrylic acid, methyl methacrylate, methacrylate ester and a polymer, to a composition, to chemical products comprising at least one of methacrylic acid, methyl methacrylate, methacrylate ester, a polymer
  • Methacrylic acid (MAA) and polymethacrylic acid (PMAA) are important industrial products with applications in, for example, thickening agents, suspending agents, flocculants, resins and absorbent materials, among other applications.
  • MAA Methacrylic acid
  • PMAA polymethacrylic acid
  • esters in particular of methyl methacrylate and polymethyl methacrylate, as well as special esters for specific applications.
  • Methyl methacrylate is a valuable industrial product with estimated current worldwide production of 3.3 million metric tons per year. It is principally used in the production of polymethyl methacrylate (PMMA) acrylic plastics.
  • PMMA materials have high transparency, weathering stability and resistance to scratching, as well as being easily moulded, light and having high breaking strength. They are used, among other applications, in automobile and transportation systems, in optics and communications, in medical technology and in construction and lighting.
  • co-polymers such as the co-polymer methyl methacrylate-butadiene-styrene (MBS), which is used as a modifier for PVC; in paints and varnishes such as waterborne coatings, for example latex house paint; in adhesives; and more recently in plates that keep light spread evenly across LCD computer and TV screens, for example in flat screens, and in contact lenses.
  • MFS co-polymer methyl methacrylate-butadiene-styrene
  • Methyl methacrylate is also used in preparation of corrosion casts of anatomical organs, such as coronary arteries of the heart.
  • Special methacrylate ester derivatives for example, of alkyl and aryl alcohols, hydroxyalcohols, polyethylene glycols, quaternary ammonium derivatives and aminoalcohols, among others, have applications in, for example, contact lenses, coatings, drug delivery, controlled release of active substances, adhesives, lubricants, flow improvers, compatibility agents for polymer blends, bonding agents, food packaging, lacquers and PVC-free underseal compounds for automobile manufacture.
  • methyl methacrylate such as those based on hydrolysis of acrylonitrile or on the reaction of acetylene, carbon monoxide and an alcohol in the presence of a nickel carbonyl complex.
  • An acetone cyanohydrin (ACH) route with acetone and hydrogen cyanide as raw materials, is also applied.
  • a disadvantage of these routes is the extremely high toxicity of nickel carbonyl and acetone cyanohydrin.
  • a preferred route is the esterification of methacrylic acid with methanol.
  • isobutylene or TBA is oxidised on suitable catalysts, first to methacrolein and then further to methacrylic acid. Either the methacrolein or the methacrylic acid is then esterified with methanol, in the case of methacrolein in an oxyesterification reaction, to form the desired methacrylate.
  • the isobutylene used in this process is often obtained by splitting of methyl tert-butyl ether (MTBE) to provide isobutylene and methanol, together with side products including dimethyl ether and tert- butyl alcohol (TBA), as well as unreacted MTBE.
  • MTBE methyl tert-butyl ether
  • Isobutylene can also be obtained from splitting of ethyl tert -butyl ether (ETBE) to afford principally isobutylene and ethanol, together with side products. It has long been known, for example from EP 0 068 785 A1 , that the presence of side products in the low-boiling isobutylene fraction is problematic for subsequent reactions of the isobutylene, in particular in oxidation to methacrylic acid. The isobutylene fraction must therefore generally be purified by removing the side products, as well as methanol or ethanol, before it can be subjected to oxidation to methacrylic acid.
  • EBE ethyl tert -butyl ether
  • So-called oxyesterification processes are also known, for example from US 4,060,545 , US 4,014,925 , US 3,925,463 , US 3,758,551 , US 5,670,702 where oxidation of a propylene or isobutylene and esterification of the oxidised product to an acrylate or a methacrylate takes place in the same reactor.
  • These documents do not address the problem of purification of isobutylene before its oxidation.
  • An object of the present invention was thus to at least partially overcome some of the problems associated with the prior art. It was particularly desired to avoid the use of highly toxic chemicals in the production of methyl methacrylate.
  • a further object was to provide a more economical and simpler process for producing methyl methacrylate from a C 4 feedstock such as isobutylene and/or TBA.
  • a particular object of the invention was to reduce the purification effort required for isobutylene before its oxidation.
  • the feed composition preferably comprises isobutylene and/or TBA, as well as methanol and/or dimethyl ether and/or formaldehyde as co-compound, more preferably isobutylene and/or TBA with methanol or isobutylene and/or TBA with dimethyl ether, preferably isobutylene with dimethyl ether. Any or all of these can be optionally purified by suitable techniques known to the skilled person, such as distillation, extraction, chromatography, washing, crystallisation or the like, before being provided to the feed composition.
  • TBA is to be comprised as feed compound in the feed composition
  • this may be obtained commercially, prepared from isobutylene and water, for example from a source of isobutylene as described above, or alternatively obtained from propene oxide production via hydroperoxydation as described in US 5424458 , US 5436376 , US 5274138 , Ullmans encyclopedia, 5th Edition, Vol. A4, p.492 and references cited therein.
  • the feed composition provided in step a) is obtained by splitting of methyl tert-butyl ether or of ethyl tert-butyl ether (ETBE).
  • MTBE is widely used as feedstock for isobutylene and splitting of MTBE is well known in the art. Splitting of ETBE can be achieved as for MTBE.
  • splitting of MTBE or ETBE can occur by any suitable means which are known to the skilled person. Suitable catalysts and reaction conditions are described, for example, in EP 1 149 814 A1 , WO 04/018393 A1 , WO 04/052809 A1 ; Ullmann's Encyclopedia of Industrial Chemistry, 5th Edition, Vol. A4, p.
  • the two main products of MTBE splitting are isobutylene and methanol.
  • the two main products of ETBE splitting are isobutylene and ethanol.
  • Further components which are often also present in the splitting phase resulting from the MTBE splitting are, among others, dimethyl ether, tert-butyl alcohol, methyl sec-butyl ether (MSBE) and unreacted MTBE.
  • Further components present in the splitting phase resulting from the ETBE splitting can be diethyl ether, tert -butyl alcohol, ethyl sec-butyl ether (ESBE) and unreacted ETBE.
  • the splitting phase may be provided directly as feed composition without purification.
  • the splitting phase obtained from an MTBE or ETBE splitting reaction is subjected to at least one of at least partial separation and/or purification before being used as feed composition. Suitable purification and separation processes are described, for example, in EP 1 149 814 A1 , WO 04/018393 A1 and WO 04/052809A1 .
  • at least a part of at least one co-compound is separated from the optionally purified splitting phase to form a co-compound phase and a depleted splitting phase which is depleted in the separated at least one co-compound.
  • the depleted splitting phase which comprises isobutylene as main component can then be optionally purified and provided as feed composition.
  • Suitable purification methods are known to the person skilled in the art and preferably comprise at least one of distillation, extraction, adsorption, absorption, chromatography or washing, preferably at least one of distillation and extraction, preferably at least one distillation and at least one extraction. It is preferred that in this process step at least one of methanol, MTBE, ethanol and ETBE is at least partially separated from the isobutylene phase. Separated MTBE and ETBE can be optionally purified and at least partially recycled to the splitting reaction.
  • the separated co-compound phase which preferably comprises methanol as main component in the case of MTBE splitting and ethanol as main component in the case of ETBE splitting, preferably corresponds to the at least one further part of the at least one co-compound which is subjected to esterification in step c).
  • At least a first part of the at least one co-compound can be subjected to the catalytic reaction zone in step b).
  • This first part of the at least one co-compound preferably at least partially reacts in step b) with at least a part of at least one oxidation product of isobutylene and/or TBA, preferably with methacrolein or methacrylic acid, to form methyl methacrylate.
  • the oxidation phase exiting the catalytic reaction zone thus preferably comprises methacrylic acid as main product, as well as at least a part of methyl methacrylate.
  • the feed composition has a content of not less than 5 ppm, preferably not less than 6 ppm, preferably not less than 7 ppm, preferably not less than 8 ppm, more preferably not less than 9 ppm and yet more preferably not less than 10 ppm of the at least one co-compound as at least a first part of the at least one co-compound.
  • An upper limit for the content of co-compound in the feed composition is about 50 wt.%, based on the feed composition.
  • the feed composition comprises at least a first part of the at least one co-compound in a range from 0.0005 to 10 wt.%, preferably from 0.0008 to 8 wt.%, more preferably from 0.001 to 7 wt.%, yet more preferably from 0.001 to 6 wt.%, more preferably from 0.001 to 5 wt.%, more preferably from 0.005 to 4 wt.%, more preferably from 0.01 to 3 wt.%, even more preferably from 0.1 to 2.7 wt.%, more preferably from 0.5 to 2.5 wt.%.
  • a source of oxygen which source is not limited and can be any suitable source of oxygen (O 2 ) such as peroxide, molecular oxygen or oxygen-enriched or oxygen-comprising gas, whereby air is preferred as oxygen source for economic reasons.
  • An O 2 source is understood here to be any compound or composition that comprises or liberates O 2 .
  • the amount of molecular oxygen provided as O 2 or as O 2 source is preferably from about 0.5 to about 20 moles, preferably from about 1 to about 10 moles O 2 per mole of isobutylene and/or TBA, more preferably from about 1 to about 5 moles O 2 per mole of isobutylene and/or TBA, more preferably from about 1 to about 3 moles O 2 per mole of isobutylene and/or TBA, more preferably from about 1 to about 2 moles O 2 per mole of isobutylene and/or TBA.
  • Water and/or water vapour can also be added to the feed composition.
  • water and/or water vapour is added to the feed composition it is preferred that from about 1 to about 20 moles, preferably from about 1 to about 15 moles, preferably from about 1 to about 10 moles, more preferably from about 1 to about 8 moles of water and/or water vapour is added to the feed composition, per mole of isobutylene and/or TBA. It may not be preferred to comprise water and/or water vapour in the feed composition at the start of step b) to the extent that TBA is comprised therein.
  • At least one diluent is added to the feed composition, which diluent can comprise inorganic or organic solvent or a gas, preferably at least one diluent gas which is inert under the reaction conditions, preferably selected from nitrogen, argon, carbon dioxide, whereby nitrogen gas and/or carbon dioxide, preferably carbon dioxide recycled from a combustion unit, preferably a catalytic or thermal combustion unit, is preferred as diluent gas.
  • the feed composition is preferably subjected to oxidation to obtain at least one oxidation product of isobutylene and/or TBA.
  • the oxidation is preferably a catalytic oxidation, preferably a gas phase catalytic oxidation.
  • Suitable reaction conditions for gas phase catalytic oxidation are, for example, temperatures of from about 250 °C to about 450 °C, preferably from about 250 °C to about 390 °C and pressures of from about 1 atm. to about 5 atm.
  • the space velocity can vary from about 100 to about 6000 hr -1 (NTP) and preferably from about 500 to about 3000 hr -1 .
  • Oxidation for example gas phase catalytic oxidation, of C 4 feeds such as isobutylene to methacrolein and/or methacrylic acid, as well as catalysts therefor, are well known in the literature, for example from US 5,248,819 , US 5,231,226 , US 5,276,178 , US 6,596,901 B1 , US 4,652,673 , US 6,498,270 , US 5,198,579 , US 5,583,084 .
  • the at least one oxidation product of isobutylene and/or TBA can be any oxygen-comprising product based on isobutylene and/or TBA, preferably at least one C 4 oxidation product such as a C 4 alcohol, a C 4 aldehyde or a C 4 acid, whereby at least one of methacrolein and/or methacrylic acid are preferred oxidation products.
  • C 4 oxidation product such as a C 4 alcohol, a C 4 aldehyde or a C 4 acid, whereby at least one of methacrolein and/or methacrylic acid are preferred oxidation products.
  • the oxidation in step b) takes place in a single oxidation stage. If the process according to the invention comprises a single oxidation stage in step b), it is preferred that the resulting oxidation phase comprises methacrylic acid as main component.
  • the oxidation in step b) takes place in at least two separate oxidation stages, preferably in two separate oxidation stages.
  • These at least two oxidation stages can be oxidation stages within a same area of the catalytic reaction zone, for example if the catalytic reaction zone is in the form of one or more reactors, a first oxidation stage can be in a first oxidation area in a reactor and a further oxidation stage can be in a further oxidation area downstream of the first oxidation area in the same reactor, or a first oxidation stage can be in a first reactor and a further oxidation stage can be in a further reactor.
  • first oxidation stage and the further oxidation stage are at different temperatures, and preferably that the first oxidation stage and the further oxidation stage are separated by an intermediate area at a different temperature to that of either of the first and further oxidation stages.
  • the at least one co-compound can be provided in the feed composition in the first oxidation stage and/or in the feed composition in a subsequent oxidation stage.
  • the at least one co-compound can be provided in the feed composition in the first and/or the second oxidation stage.
  • the at least one co-compound is provided in the feed composition in the second oxidation stage of a two-stage oxidation.
  • the amount of O 2 provided is preferably from about 0.5 to about 10 moles, preferably from about 1 to about 5 moles, more preferably from about 1 to about 3 moles, preferably from about 1 to about 2 moles O 2 per mole of isobutylene and/or TBA, and a preferred amount of water and/or water vapour is in the range from 0 to about 20 moles, preferably from 0 to about 10 moles, more preferably from 0 to about 5 moles H 2 O per mole of isobutylene and/or TBA, whereby a molar ratio O 2 : isobutylene and/or TBA : water and/or water vapour of about 2 : 1 : 0 is preferred if mainly TBA is provided as C 4 feedstock in the feed composition and about 2 : 1 : 1 if mainly isobutylene is provided as C 4 feedstock in the
  • the amount of O 2 provided is preferably from about 0.5 to about 10 moles, preferably from about 1 to about 5 moles, more preferably from about 1 to about 3 moles O 2 per mole of isobutylene and/or TBA, and a preferred amount of water and/or water vapour is in the range from about 1 to about 20 moles, preferably from about 1 to about 10 moles, more preferably from about 2 to about 8 moles H 2 O per mole of isobutylene and/or TBA, whereby a preferred molar ratio O 2 : isobutylene and/or TBA : water and/or water vapour in a second oxidation stage is in the range of about 2 : 1 : 2 - 6, preferably in the range of about 2 : 1 : 3 - 5, based on the number of moles of isobutylene and/or TBA provided in the feed composition in the first oxidation stage.
  • At least one diluent is added to the isobutylene phase, which diluent can comprise inorganic or organic solvent or a gas, preferably at least one diluent gas which is inert under the reaction conditions, preferably selected from nitrogen, argon and carbon dioxide, whereby nitrogen gas and/or carbon dioxide, preferably carbon dioxide recycled from a catalytic or thermal combustion unit, preferably from a catalytic combustion unit, is preferred as diluent gas.
  • the main product of a first oxidation stage is methacrolein and the main product of a further oxidation stage is methacrylic acid.
  • the presence of the at least one co-compound results in a yield of methacrylic acid which is reduced compared to the expected yield of methacrylic acid if the same reaction is carried out on isobutylene in the absence of the at least one co-compound. This reduction is, however, compensated by the unexpected formation of methyl methacrylate already during the oxidation.
  • the amount of methyl methacrylate present in the oxidation phase is dependent on the amount of co-compound present in the feed composition and on the conversion thereof to methyl methacrylate under the oxidation conditions. It has been found, for example, that when the at least one co-compound is methanol, less than half of the methanol is oxidised to formaldehyde, while up to about 50% of the methanol reacts to methyl methacrylate. An amount of about 2 wt.% methanol, based on the hydrocarbons in the feed composition, in the feed composition thus results in an oxidation phase comprising about 1 wt.% methyl methacrylate, based on the hydrocarbons in the oxidation phase. A similar conversion is also obtained if dimethyl ether is present as co-compound.
  • the oxidation phase preferably comprises at least 0.0005 wt.%, preferably at least 0.0008 wt.%, more preferably at least 0.001 wt.%, more preferably at least 0.005 wt.%, yet more preferably at least 0.01 wt.%, more preferably at least 0.05 wt.%, preferably at least 0.1 wt.%, preferably at least 0.3 wt.%, more preferably at least 0.5 wt.%, more preferably at least 0.8 wt.%, yet more preferably at least 1 wt.%, even more preferably 1.5 wt.%, more preferably at least 1.2 wt.%, more preferably at least 1.5 wt.%, even more preferably at least 1.8 wt
  • the oxidation phase is preferably subjected to at least one of quenching and/or purification to isolate the methacrylic acid, preferably the methacrylic acid and the methyl methacrylate, and to remove unreacted feed composition compounds such as methacrolein and/or undesired side products arising from the reaction or reactions in the catalytic reaction zone.
  • the quenching can be carried out by any suitable quenching process known to the skilled person, as described for example in Offenlegungsschrift DE 21 36 396 , EP 297 445 A2 , EP 297 788 A2 , JP 01193240 , JP 01242547 , JP 01006233 , US 2001/0007043 A1 , US 6,596,901 B1 , US 4,956,493 , US 4,618,709 B1 , US 5,248,819 , whose disclosure concerning quenching of acrylic and methacrylic acids is hereby incorporated and forms part of the present disclosure.
  • Preferred quenching agents are water and organic solvents such as, for example, aromatic or aliphatic hydrocarbons, or mixtures of at least two thereof, whereby preferred organic solvents have relatively low vapour pressure under the quenching conditions, such as heptane, toluene or xylene.
  • the purification can be carried out by any suitable purification means known to the skilled person, such as by distillation, crystallisation, extraction, absorption or precipitation, preferably by crystallisation.
  • methacrolein is separated.
  • the separated methacrolein can be recycled to the catalytic reaction zone, whereby if the catalytic reaction zone comprises more than one oxidation stage the separated methacrolein is preferably recycled to a further oxidation stage, preferably to the second oxidation stage of a catalytic reaction zone comprising two oxidation stages.
  • the separated methacrolein can be further subjected to oxidation, thereby leading to increased efficiency of the overall process and increased yields of methacrylic acid and methyl methacrylate.
  • Methacrylic acid produced in steps a) and b) above can be at least partially collected, or it can be conducted to further reactions or processes.
  • At least one polymerisation inhibitor is preferably added to the methacrylic acid.
  • the generally optionally but in some cases necessarily quenched and/or purified oxidation phase comprising at least one oxidation product is subjected to esterification in step c), optionally in the presence of a polymerisation inhibitor to prevent polymerisation of methacrylic acid and/or methyl methacrylate.
  • esterification in step c) is not particularly limited.
  • the esterification can be carried out, for example, as described in US 6,469,202 , JP 1249743 , EP 1 254 887 A1 , US 4,748,268 , US 4,474,981 , US 4,956,493 or US 4,464,229 whose disclosures concerning esterification of acrylic and methacrylic acids are hereby incorporated and form part of the present disclosure.
  • An oxyesterification is also possible, for example as described in the literature cited above.
  • At least a further part of said at least one co-compound preferably at least 80 wt.%, more preferably at least 90 wt.% and most preferably in the range from 95 to 99 wt.%, each based on said at least one co-component, is subjected to esterification in step c).
  • this at least one further part of the at least one co-compound is separated from the at least one part of the at least one co-compound before providing the at least one co-compound to the feed composition.
  • the at least one further part of the at least one co-compound is separated from the feed composition before subjecting the feed composition to the catalytic reaction zone.
  • the separated at least one further part of the at least one co-compound can then be provided again, for example by combining it with the optionally quenched and/or purified oxidation phase before and/or during the esterification in step c), and subjected to esterification together with the optionally quenched and/or purified oxidation phase.
  • This aspect is particularly preferred if at least methanol is present as co-compound.
  • the at least one further part of the at least one co-compound can be subjected to purification before it is subjected to the esterification in step c). Suitable purification techniques are known to the skilled person, for example those mentioned above in connection with the at least one co-compound in the feed composition.
  • the esterification phase produced is step c) is optionally subjected to a purification, whereby preferably methyl methacrylate is separated from other esterification phase components such as unreacted methanol and/or methacrylic acid and other impurities.
  • Suitable purification methods are known to the person skilled in the art and preferably comprise at least one of distillation, crystallisation, extraction, chromatography or washing more preferably at least one distillation device.
  • Separated methanol and/or methacrylic acid can be recycled to other reaction steps, or to the esterification step, optionally after purification, or can be collected.
  • any or all of steps a) to c) occur at least partially in liquid phase and/or in the gas phase.
  • all steps occur at least partially in liquid phase, that all steps occur at least partially in the gas phase, or that at least one step occurs at least partially in the liquid phase and the remaining step or steps occur at least partially in the gas phase.
  • steps a) and b) occur at least partially in the gas phase and step c) at least partially in the liquid phase, or steps a), b) and c) occur at least partially in the liquid phase. It is particularly preferred according to the process according to the invention that at least step b) occurs at least partially in the gas phase.
  • step b) comprises at least two oxidation stages, it is possible that at least one oxidation stage occurs at least partially in liquid phase and at least one oxidation stage occurs at least partially in the gas phase.
  • step b) occurs at least partially in the gas phase, it is preferred that a quenching step as described above is carried out prior to purification of the oxidation phase.
  • step b) the oxidation takes place in two separate oxidation stages
  • one or both of the oxidation stages are gas phase or liquid phase oxidation stages.
  • one oxidation stage is a gas phase oxidation stage and the other oxidation stage is a liquid phase oxidation stage.
  • the first and second oxidation stages are gas phase oxidation stages.
  • the first oxidation stage is a gas phase oxidation stage and the second oxidation stage is a liquid phase oxidation stage.
  • the esterification of step c) is a liquid phase esterification. If the second oxidation stage is a liquid phase oxidation stage it is also possible that this second oxidation stage is combined with step c) into a combined liquid phase oxidation-esterification stage.
  • a quenching step takes place between at least two of the at least two separate oxidation stages.
  • This quenching step is preferably a quenching step enabling isolation of methacrolein.
  • This embodiment can be particularly preferred if a second or further oxidation stage is a liquid phase oxidation stage, or if a second or further oxidation stage is combined with step c) into a combined liquid phase oxidation-esterification stage. Quenching of this type can be carried out by any suitable method known to the skilled person. Suitable methods are described, for example, in DE 34 41 207 A1 and in JP 60087241 .
  • step c) occurs in the gas phase, dimethyl ether is preferred as co-compound. If step c) occurs in the liquid phase, methanol is preferred as co-compound.
  • the at least one further part of said at least one co-compound, which is subjected to esterification in step c) as described above is at least 90 wt.%, more preferably at least 92 wt.%, more preferably at least 93, 94, 95 or 96 wt.%, even more preferably at least 97 wt.%, yet more preferably at least 97.5 wt.%, more preferably at least 98 wt.% of the at least one co-compound.
  • the feed composition is obtained from splitting of MTBE, it is preferred that at least 90 wt.%, more preferably at least 92 wt.%, more preferably at least 93, 94, 95 or 96 wt.%, even more preferably at least 97 wt.%, yet more preferably at least 97.5 wt.%, more preferably at least 98 wt.% of the methanol produced in the splitting is separated from the splitting phase, optionally purified, and subjected to esterification in step c).
  • an apparatus for production of methacrylic acid comprising:
  • the supply can be any means suitable for supplying a feed composition to the catalytic reaction zone, for example a reservoir, a pipe, a line, a tube, or the like.
  • the supply should preferably be resistant to elevated and/or decreased temperature and/or pressure, preferably resistant at least to temperatures and pressures as described above for a preferred oxidation reaction. A good temperature and/or pressure resistance is particularly preferred if one or more of the reactions which should take place in the apparatus is a gas phase reaction.
  • the supply is furthermore preferably not reactive with any of the components of the feed composition, nor with any further component such as oxygen or an oxygen equivalent, water or water vapour, diluent, which might be added to the feed composition, as mentioned above in connection with the process according to the invention.
  • Any supply which is intended to supply a gaseous phase or composition is preferably maintained at a temperature above the dewpoint temperature of the gas to be supplied. This can be achieved, for example, by heating or by thermally insulating the supply.
  • the supply is preferably in fluid communication with a methyl tert -butyl ether or ethyl tert -butyl ether splitting unit.
  • the term "in fluid communication” is understood here as meaning that the supply is connected with the splitting unit such that a fluid, which can be at least one of a liquid, a gas, a vapour, a supercritical fluid or any other fluid, can be conveyed and or transported by any means, preferably flow, from the supply to the splitting unit or from the splitting unit to the supply.
  • the catalytic reaction zone preferably comprises at least one oxidation unit.
  • the at least one oxidation unit is preferably at least one oxidation unit suitable for carrying out oxidation of isobutylene and/or TBA to at least one of methacrolein and methacrylic acid, preferably comprising at least one oxidation catalyst.
  • the at least one oxidation unit can be, for example, a multitube reactor such as a tube and shell reactor, a plate reactor or a fluidised bed reactor, whereby a multitube reactor is preferred, preferably a multitube reactor packed with oxidation catalyst.
  • Such reactors are commercially available, for example from MAN DWE GmbH, Deggendorfer Werft, Germany, or from Ishikawajima-Harima Heavy Industries (IHI Corporation from 01 July 2007), Japan, and form part of the general knowledge of the person skilled in the art.
  • the catalytic reaction zone comprises one oxidation area, preferably one oxidation unit, preferably one oxidation reactor, whereby it is preferred that this oxidation area comprises at least one catalyst, preferably a catalyst capable of oxidation of at least one of isobutylene and TBA to at least one of methacrolein and methacrylic acid, preferably to methacrylic acid.
  • the catalytic reaction zone preferably the at least one oxidation unit, comprises at least a first oxidation area and a further oxidation area, preferably a first oxidation area and a second oxidation area.
  • the first oxidation area and the further oxidation area preferably the first oxidation area and the second oxidation area, can be different oxidation areas in a single reactor, or they can each be in a separate respective reactor, with all reactors being in fluid communication with each other.
  • a first oxidation stage is preferably in a first oxidation area in a reactor and a further oxidation stage is then in a further oxidation area downstream of the first oxidation area in the same reactor.
  • the reactor is a multitube reactor as described above.
  • at least one oxidation catalyst preferably at least two oxidation catalysts, are provided, preferably in a layered-type fashion, preferably such that a first oxidation stage occurs at at least one upstream catalyst layer and a further oxidation stage at least one further catalyst layer downstream thereof.
  • Catalyst layers in a same tube can be directly adjacent to each other.
  • At least one catalyst layer is separated from at least one other catalyst layer by at least one intermediate area, for example at least one mixing area or at least one transition area, e.g. at least one transition area between an area with a certain number of tubes and an area with a different number of tubes, or by means of layers of, for example, packing materials or suspending agents which are inert under the reaction conditions.
  • the first oxidation area and the further oxidation area are in separate reactors, it is preferred that all reactors are multitube reactors.
  • at least one reactor is a liquid phase reactor, for example a liquid phase oxyesterification reactor, this reactor is preferably not a multitube reactor.
  • first oxidation area and the further oxidation area or areas are at different temperatures. It is further preferred that the first and further oxidation areas, in particular if they are at different temperatures with respect to each other, are separated by an intermediate area which is at a different temperature to that of either of the first and further oxidation stages.
  • the apparatus according to the invention comprises a first oxidation reactor and at least one further oxidation reactor as described above, it is possible that a quenching unit is provided after the first oxidation reactor and before at least one further oxidation reactor, preferably between the first and second oxidation reactors.
  • This quenching unit preferably serves to isolate methacrolein.
  • a quenching unit between the first oxidation reactor and at least one further oxidation reactor is preferred if the first oxidation reactor is a gas phase reactor and the at least one further reactor is a liquid phase reactor.
  • Quenching units suitable for use in the apparatus are preferably those as described, for example, in the references cited above in connection with a quenching process step.
  • the apparatus comprises a first oxidation area and a further oxidation area
  • the first oxidation area comprises a first oxidation catalyst and the further oxidation area comprises a further oxidation catalyst
  • the further oxidation area is preferably a second oxidation area
  • the further oxidation catalyst is preferably a second oxidation catalyst.
  • the first oxidation catalyst is preferably a catalyst for oxidation of isobutylene to methacrolein
  • the further oxidation catalyst, preferably the second oxidation catalyst is preferably a catalyst for oxidation of methacrolein to methacrylic acid.
  • the first and further catalysts are not particularly limited and are preferably solid catalysts suitable for the oxidation, preferably mixed metal oxide catalysts.
  • Such catalysts are well known in the art, for example as described in JP 58059934 , JP 55045617 , EP 0 005 769 A1 , EP 1 350 566 A2 , EP 0 450 596 A2 , EP 0 456 837 A1 , WO 2001/098247 A2 , EP 0 630 879 A1 , US 2002/0198406 A1 , EP 911 313 , US 5,602,280 , EP 145 469 , US 5,218,146 , US 4,365,087 , US 5,077,434 , US 5,231,226 or US 2003/0004374 A1 , US 6,498,270 B1 , US 5,198,579 , EP 1 595 600 A1 , EP 1052 016 A2 , US 5,583,084 , and references cited therein,
  • At least one supply for at least one O 2 source preferably at least one supply for air, and at least one supply for water and/or steam
  • the at least one supply for at least one O 2 source and the at least one supply for water and/or steam provide respectively at least one O 2 source and water and/or steam directly to the catalytic reaction zone.
  • the apparatus preferably comprises at least one supply for at least one O 2 source and at least one supply for water and/or steam for each oxidation area.
  • the apparatus can further comprise a supply for a diluent such as nitrogen, argon and/or carbon dioxide, preferably nitrogen or carbon dioxide, preferably carbon dioxide-comprising recycle gas from a catalytic combustion unit (CCU) or a thermal combustion unit (TCU), preferably from a catalytic combustion unit.
  • a diluent such as nitrogen, argon and/or carbon dioxide, preferably nitrogen or carbon dioxide, preferably carbon dioxide-comprising recycle gas from a catalytic combustion unit (CCU) or a thermal combustion unit (TCU), preferably from a catalytic combustion unit.
  • the apparatus according to the invention optionally comprises at least one first purification unit downstream of the catalytic reaction zone.
  • the at least one first purification unit is upstream of the esterification unit, preferably between and in fluid communication with the catalytic reaction zone and the esterification unit.
  • the at least one second purification unit is preferably suitable for purification of methacrylic acid, preferably for separation of methacrylic acid from water and/or terephthalic acid (TPA), and preferably comprises at least one of a distiller, a crystalliser, an extractor, a wash device and a column. It is particularly preferred that the at least one first purification unit comprises at least one crystalliser.
  • the at least one first purification unit comprises more than one purification stage. Unreacted methacrolein can be separated here and, if desired, conducted back to the catalytic reaction zone for further reaction. Suitable purification units are described in the references cited above in connection with a process step for purification of methacrylic acid.
  • At least one quench unit is comprised between and in fluid communication with the catalytic reaction zone and the purification unit. It is preferred that methacrylic acid present in the oxidation phase leaving the catalytic reaction zone is condensed in the quench unit to form a solution comprising methacrylic acid as main oxidation product. Unreacted methacrolein can also be separated in the quench unit and, if desired, conducted back to the catalytic reaction zone for further reaction. Quench units suitable for use in the apparatus according to the invention are described, for example, in the references cited above in connection with a quenching process step and an intermediate quenching step.
  • the esterification unit is not particularly limited and can be any unit suitable for esterification to form methyl methacrylate. It is preferably suitable for liquid phase esterification.
  • the esterification unit preferably comprises an esterification catalyst, which can be a heterogeneous or homogeneous catalyst such as a solid state catalyst or a liquid catalyst, and is preferably an acidic ion exchange resin such as those described in US 6,469,292 , JP 1249743 , EP 1 254 887 A1 or commercially available under the trade name names Amberlyst ® (Rohm and Haas Corp.), Dowex ® , (Dow Corp.) or Lewertit ® (Lanxess AG), or an acid capable of catalysing esterification, such as sulphuric acid, H 2 SO 4 .
  • an esterification catalyst which can be a heterogeneous or homogeneous catalyst such as a solid state catalyst or a liquid catalyst, and is preferably an acidic ion
  • the conduit unit is preferably in fluid communication with at least the supply and the esterification unit. If an MTBE or ETBE splitter is comprised in the apparatus, the conduit unit is preferably also connected to the MTBE or ETBE splitter, preferably between the MTBE or ETBE splitter and the supply, as well as between the MTBE or ETBE splitter and the esterification unit.
  • the conduit unit comprises means for separating at least a part of the at least one co-compound.
  • Such means can be, for example, a distiller, a column, an extractor, a tap, a pipe, a valve, a regulator, a phase separator, or any other means known to the skilled person and appearing suitable for separating a liquid from a liquid, a liquid from a gas and/or vapour or a gas and/or vapour from a gas and/or vapour.
  • the apparatus preferably comprises, between a splitting unit and the catalytic reaction zone, or between the conduit unit and the supply or between the MTBE or ETBE splitter and the conduit unit and preferably in fluid communication with at least two thereof, at least one separation and/or purification unit for separation and/or purification of an isobutylene phase from the effluent of the splitting unit.
  • the separation and/or purification unit can be at least one of an extractor, a crystalliser, a column, a distillation device, a rectification device, a membrane, a pervaporation device, an adsorption unit, an absorption unit and a wash device.
  • the apparatus can further comprise at least one third purification unit between the conduit unit and the esterification unit.
  • the third purification unit or units is preferably at least one purification unit for at least one co-compound, preferably for methanol.
  • Suitable purification units are known to the person skilled in the art and preferably comprise at least one distillation device, crystalliser, extractor, column or wash device, more preferably at least one distillation device.
  • An example of a purification unit for methanol is described in EP 1 254 887 A1 .
  • the apparatus may further comprise at least one fourth purification unit downstream of the esterification unit, for purification of methyl methacrylate.
  • Suitable purification units are known to the person skilled in the art and preferably comprise at least one distillation device, crystalliser, extractor, column or wash device, more preferably at least one distillation device.
  • the at least one fourth purification unit should enable the at least partial purification of methyl methacrylate and at least partial separation of side products, for example impurities arising from the esterification, unreacted methanol and/or methacrylic acid. Unreacted reagents can optionally be recycled into the esterification reaction, optionally after being subjected to purification.
  • the invention also relates to a process according to the invention for preparation of methacrylic acid, wherein said process is performed in an apparatus according to the invention.
  • the invention also relates to methacrylic acid obtainable by a process according to the invention.
  • the invention also relates to a process according to the invention for preparation of methyl methacrylate, wherein said process is performed in an apparatus according to the invention.
  • the invention also relates to methyl methacrylate obtainable by a process according to the invention.
  • the methacrylate ester derivatives can be prepared in step ⁇ 3 from methyl methacrylate by methods known to the skilled person, for example by transesterification. Alternatively, these derivatives may be prepared in step ⁇ 3 by esterification of methacrylic acid according to the invention with the respective alcohol. In a further possible preparation of the hydroxyester derivatives, methacrylic acid according to the invention is reacted in a ring-opening reaction with a corresponding oxygen-comprising ring, for example an epoxide, in particular ethylene oxide or propylene oxide.
  • Preferred methacrylate esters are alkyl methacrylates, in particular butyl methacrylates, in particular n-butyl methacrylate, isobutyl methacrylate, hydroxyester methacrylate derivatives, for example hydroxyethyl methacrylate, preferably 2-hydroxyethyl methacrylate, and hydroxypropyl methacrylate, preferably 2-hydroxypropyl methacrylate or 3-hydroxypropyl methacrylate, and special methacrylate esters ethyl methacrylate, 2-ethylhexyl methacrylate, isodecyl methacrylate, cyclohexyl methacrylate, isobornyl methacrylate, benzyl methacrylate, 3,3,5-trimethyl cycl
  • the polymerisation is not particularly limited and can be carried out by any method known to the skilled person and appearing suitable, for example as described in US 5,292,797 , US 4,562,234 , US 5,773,505 , US 5,612,417 , US 4,952455 , US 4,948,668 , US 4,239,671 .
  • Preferred polymerisation methods are radical polymerisation, initiated by initiators which decompose into radicals under the polymerisation conditions, whereby the polymerisation is preferably a solution or an emulsion polymerisation, preferably an aqueous solution polymerisation.
  • acrylamides and methacrylamides acrylic acid esters and other methacrylic acid esters, such as methyl acrylate, ethyl acrylate, propyl acrylate or butyl acrylate, ethyl methacrylate, propyl methacrylate or butyl methacrylate, as well as acetates such as vinyl acetate, styrene, butadiene and acrylonitrile.
  • the at least one co-monomer is most preferably at least one co-monomer selected from the group consisting of: styrene, butadiene, acrylonitrile, butyl acrylate, vinyl acetate, methyl acrylate.
  • the polymerisation can also take place in the presence of one or more crosslinkers.
  • Preferred cross-linkers according to the invention are compounds which have at least two ethylenically unsaturated groups in one molecule, compounds which have at least two functional groups which can react with functional groups of the monomers in a condensation reaction, in an addition reaction or a ring-opening reaction, compounds which have at least one ethylenically unsaturated group and at least one functional group which can react with functional groups of the monomers in a condensation reaction, an addition reaction or a ring-opening reaction, or polyvalent metal cations.
  • the invention also relates to a polymer obtainable according to a process according to the invention or comprising at least one monomer unit selected from a methacrylic acid monomer according to the invention or obtainable by a process according to the invention and a methyl methacrylate monomer according to the invention or obtainable by a process according to the invention and a methacrylate ester according to the invention or obtainable by a process according to the invention, as well as optionally other components such as a co-monomer and optionally a crosslinker.
  • the invention also relates to a process for producing a composition comprising at least a first component selected from at least one of methacrylic acid according to the invention, methyl methacrylate according to the invention, a methacrylate ester according to the invention, and a polymer comprising at least one monomer unit selected from methacrylic acid, methyl methacrylate and a methacrylate ester, comprising the steps:
  • the at least one further component is preferably at least one component selected from natural or synthetic organic or inorganic polymers, for example selected from a substituted or unsubstituted polystyrene, poly-n-butyl acrylate, a polyacrylonitrile, a polysaccharide, a silica, and a nanomaterial.
  • the invention also relates to a composition
  • a composition comprising at least one first component selected from methacrylic acid according to the invention, methyl methacrylate according to the invention, a methacrylate ester according to the invention, and a polymer according to the invention comprising at least one monomer unit selected from methacrylic acid, methyl methacrylate and a methacrylate ester and at least one further component, or obtainable according to a process according to the invention.
  • the at least one further component is preferably at least one component as described above in connection with the process for producing a composition.
  • the invention also relates to chemical products such as a shaped article, a moulding material, a film, a sheet, a granulate, a composite, a foam, a fibre, a lubricant, an adhesive, a thickening agent, a suspending agent, a flocculant, a resin, a plastic, a coating, a contact lens, a construction material, an absorbent material, a pharmaceutical, a material for controlled release of active substances, a foam, a fibre, a lubricant, a powder or a particle comprising at least one of methacrylic acid according to the invention, methyl methacrylate according to the invention, methacrylate ester according to the invention, a polymer or co-polymer according to the invention which comprises methacrylic acid, methyl methacrylate, and/or a methacrylate ester, and a composition according to the invention.
  • chemical products such as a shaped article, a moulding material, a film, a sheet
  • the invention also relates to a use of at least one of methacrylic acid according to the invention, methyl methacrylate according to the invention, methacrylate ester according to the invention, a polymer or co-polymer according to the invention which comprises methacrylic acid, methyl methacrylate, and/or a methacrylate ester, and a composition according to the invention, in chemical products such as shaped articles, moulding materials, films, sheets, granulates, composites, adhesives, thickening agents, suspending agents, flocculants, resins, plastics, coatings, contact lenses, construction materials, absorbent materials, pharmaceuticals, materials for controlled release of active substances, foams, fibres, lubricants, powders, particles.
  • chemical products such as shaped articles, moulding materials, films, sheets, granulates, composites, adhesives, thickening agents, suspending agents, flocculants, resins, plastics, coatings, contact lenses, construction materials, absorbent materials, pharmaceuticals, materials for controlled release of
  • FIG. 1 shows schematically a preferred embodiment of the apparatus 1 according to the invention.
  • a gaseous feed composition comprising at least one of isobutylene, TBA and methacrolein as main component and at least one of methanol, ethanol, dimethyl ether, MTBE, ETBE and formaldehyde as co-compound is provided to the catalytic reaction zone 3 from splitting unit 7 by means of supply 2.
  • the gaseous feed composition may be conducted via conduit unit 6, or conduit unit 6 may be bypassed by the gaseous feed composition by means of bypass 31, depending on the desired constitution of the feed composition.
  • Conduit unit 6 serves to regulate the flow of the feed composition towards catalytic reaction zone 3 and to regulate the constitution of the feed composition.
  • the apparatus 1 can comprise one or more pre-purification units 18 for the respective co-compounds and/or for isobutylene and/or for the feed composition.
  • the feed composition is conducted via supply 2 into the first oxidation area 9 of catalytic reaction zone 3.
  • Each oxidation area 9, 10, is supplied with air, steam and diluent by means of air supply 22, steam supply 23 and diluent supply 30 respectively.
  • Diluent supply 30 is optionally supplied with diluent by means of diluent recycle flow 33 from quench unit 15 and/or purification unit 4, optionally via a combustion unit 34 (recycle flow 33 and combustion unit 34 are not shown for the sake of clarity).
  • first oxidation unit 8a comprising first oxidation catalyst 12 (not shown), of first oxidation area 9, the gaseous feed composition is subjected to catalytic gas phase oxidation to form methacrolein as main oxidation product in a first gaseous oxidation phase.
  • the first oxidation phase then flows to second oxidation area 10a of catalytic reaction zone 3, via optional quench area 32.
  • Second oxidation area 10a comprises second oxidation catalyst 13a (not shown) in second oxidation unit 8b.
  • first oxidation phase is subjected to a second catalytic gas phase oxidation to form mainly methacrylic acid as main oxidation product in a second gaseous oxidation phase.
  • Methyl methacrylate is also formed as minor oxidation product in one or both of the oxidation areas 9 and 10a.
  • the second gaseous oxidation phase is then conducted to quench unit 15, where the methacrylic acid is condensed with a quenching agent to form a quench phase comprising methacrylic acid and impurities.
  • Unreacted methacrolein is separated from the quenched second oxidation phase and can be recycled to second oxidation area 10a via methacrolein recycle conduit 24.
  • the quench phase comprising methacrylic acid, methyl methacrylate and impurities is then conducted to purification unit 4, where methacrylic acid and methyl methacrylate are at least partially separated from the quenching agent and from the impurities.
  • Purification unit 4 can include one or more purification stages, 4a, 4b, etc. (not shown in the figure), depending on the desired degree of purity of methacrylic acid. Methacrolein can also be separated in purification unit 4, and can be recycled via methacrolein recycle conduit 24.
  • Purified methacrylic acid which is not intended for esterification can be collected from purification unit 4 via outlet 25.
  • the methacrylic acid to be converted into methyl methacrylate is conducted to esterification unit 5.
  • Esterification unit 5 comprises an esterification catalyst 16.
  • Methanol is supplied to esterification unit 5 by means of methanol supply 17, whereby a methanol purification unit 19 can be located upstream of esterification unit 5.
  • the methanol can be supplied, optionally via methanol purification unit 19, from splitting unit 7 if this is a splitting unit for MTBE, from conduit unit 6, or from a different methanol source (not shown in the figure).
  • esterification unit 5 the methacrylic acid and the methanol are esterified over esterification catalyst 16 (not shown) to form an esterification phase comprising methyl methacrylate as main esterification product, together with impurities and unreacted starting materials.
  • esterification phase can be conducted to purification unit 20, where the methyl methacrylate is separated from the reaction composition and from impurities.
  • Purification unit 20 can comprise one or more purification stages 20a, 20b, etc. depending on the desired degree of purity of methyl methacrylate. Methyl methacrylate is recovered from purification unit 20 via outlet 26.
  • Unreacted methanol and/or methacrylic acid present in the esterification phase can also be separated in purification unit 20 and removed from purification unit 20 via methacrylic acid outlet 28 and methanol outlet 29 respectively.
  • One or both of methanol and methacrylic acid can be recycled to esterification unit 5, optionally via methanol purification unit 19 and methacrylic acid purification unit 4 respectively, or one or both can be conducted away.
  • the catalytic reaction zone 3 illustrated in figure 1 as a two-stage oxidation zone can also be considered as a one-stage oxidation zone.
  • the purified isobutylene phase is conducted to catalytic reaction zone 3, comprising an oxidation area 9.
  • oxidation area 9 methacrolein is formed and converted continuously to methacrylic acid.
  • a feed composition is prepared with composition according to Table 1.
  • Table 1 Example 1 (control) (mol%)
  • Example 2 (mol%)
  • Example 3 (mol%)
  • Isobutylene 100 96.6 93.9 Methanol 0 3.4 4.7
  • the resulting composition is then subjected to a first oxidation reactor, in which IBEN was oxidised to methacrolein according to the process and under the conditions of Example 15 of EP 0 807 465 A1 .
  • a relative yield of 1.032 was obtained, i.e. an improvement of 3.2%, compared to the control (with relative yield of 1.00).
  • Example 3 One mole of the methacrylic acid obtained in Example 3 was converted to methyl methacrylate by reaction with 1.2 moles technical grade methanol, in a liquid phase reaction in a fixed bed reactor packed with an acidic ion exchange resin as described in EP 1 254 887 A1 , with the difference that Amberlyst ® (Rohm & Haas Corp.) is used as acidic ion exchange resin.
  • the conversion of methacrylic acid to methyl methacrylate was 45%, based on methacrylic acid.
  • n-Butyl methacrylate was prepared according to the process of Example 2 of DE 103 01 007 A1 by transesterification of the methyl methacrylate obtained in Example 5 above.

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EP07010480A 2007-05-25 2007-05-25 Verfahren zur Herstellung von Methylmethacrylat durch Veresterung während der Oxidation Withdrawn EP1994978A1 (de)

Priority Applications (8)

Application Number Priority Date Filing Date Title
EP07010480A EP1994978A1 (de) 2007-05-25 2007-05-25 Verfahren zur Herstellung von Methylmethacrylat durch Veresterung während der Oxidation
CN201510090209.6A CN104761447A (zh) 2007-05-25 2007-07-11 通过在氧化过程中酯化而制备甲基丙烯酸甲酯的方法
CNA2007101290656A CN101311159A (zh) 2007-05-25 2007-07-11 通过在氧化过程中酯化而制备甲基丙烯酸甲酯的方法
JP2010509756A JP5511655B2 (ja) 2007-05-25 2008-02-25 酸化中のエステル化によるメタクリル酸メチルの製造方法
KR1020097024424A KR101517633B1 (ko) 2007-05-25 2008-02-25 산화 중 에스테르화에 의한 메틸 메타크릴레이트의 제조 방법
PCT/EP2008/052225 WO2008145417A1 (en) 2007-05-25 2008-02-25 Process for preparation of methyl methacrylate by esterification during oxidation
US12/598,438 US8829235B2 (en) 2007-05-25 2008-02-25 Process for preparation of methyl methacrylate by esterification during oxidation
TW097118761A TWI455921B (zh) 2007-05-25 2008-05-21 在氧化期間藉酯化作用製備甲基丙烯酸甲酯之方法

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WO2010079293A1 (fr) 2009-01-06 2010-07-15 Arkema France Procede de fabrication d'un methacrylate de methyle derive de la biomasse
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CN101311159A (zh) 2008-11-26
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